Dual bonder

ABSTRACT

A system and method for producing a disposable undergarment, with the lateral edges of the undergarment bonded by means of an ultrasonic horn. When a blank is formed for an individual undergarment, the lateral edges of opposing edges of the blank will form the seam. When the edges are sealed together, a seam is formed. The individual undergarments may be later separated along the seams.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/395,152, filed 15 Sep. 2016.

BACKGROUND OF THE INVENTION

The present invention relates to disposable hygiene products and more specifically, to methods and apparatuses for processing disposable hygiene products such as baby diapers, adult diapers, disposable undergarments, incontinence devices, sanitary napkins and the like. More specifically, the invention relates to controlling and positioning webs or web segments of a disposable diaper and bonding them. Various types of automatic manufacturing equipment have been developed which produce the desired results with a variety of materials and configurations.

The invention disclosed herein relates to a method for controlling pieces traveling on a production line, specifically a bonding system for bonding a plurality of webs together. Although the description provided relates to diaper manufacturing, the method is easily adaptable to other applications. Although the description provided relates to bonding portions of diapers, the method is easily adaptable to other products, other disposable products, other diaper types and other portions of diapers.

SUMMARY OF THE INVENTION

The current invention is a system and method for producing a disposable undergarment, with the lateral edges of the undergarment bonded by means of an ultrasonic horn. When a blank is formed for an individual undergarment, the lateral edges of opposing edges of the blank will form the seam. When the edges are sealed together, a seam is formed. The individual undergarments may be later separated along the seams.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a system according the present invention.

FIG. 2 is a view similar to that of FIG. 1, but showing movement of the component parts to vary the distance between bonds.

FIG. 3 is an enlarged view of an anvil insert for use with the present system.

FIG. 3A is an enlarged perspective view of the anvil insert illustrated in FIG. 3.

FIG. 4 is a top view of the anvil insert illustrated in FIG. 3.

FIG. 4A is an enlarged view of FIG. 4 and showing a bond pattern.

FIG. 4B is a cross sectional view of the anvil insert illustrated in FIG. 4A, and taken along lines 4B-4B thereof.

FIG. 4C is an enlarged view of FIG. 4A.

FIG. 5 is a top plan view showing a web with spaced apart bonds.

FIG. 6 is a schematic view similar to that of FIG. 1, and showing webs moving at a non-bonding velocity.

FIG. 6A is a view similar to that of FIG. 6, but showing a front side and a back side of a folded web.

FIG. 6B is a cross sectional view taken along lines 6B-6B of FIG. 6A, and showing a back side adjacent an anvil and a front side adjacent a horn.

FIG. 7 is a schematic view similar to that of FIG. 6, and showing movement of accumulator rollers to slow the web to a bonding velocity.

FIG. 8 is a schematic view similar to that of FIGS. 6 and 7, and showing movement of accumulator rollers to increase the velocity web after bonding.

FIG. 9 is a top plan view of webs moving as illustrated in FIG. 6.

FIG. 10 is a top plan view of webs moving as illustrated in FIG. 7.

FIG. 11 is a graphic representation of the various web velocities.

FIG. 12 is a view similar to that of FIG. 1, but showing three anvils and ultrasonic horns.

FIG. 13 is a view similar to that of FIG. 12, but showing movement of the component parts to vary the distance between bonds.

FIG. 14 is a top plan view showing paired anvils and ultrasonic horns.

FIG. 15 is a view similar to that of FIG. 14, but showing movement of the component parts to vary the distance between bonds.

FIG. 16 is a view similar to that of FIGS. 1, 6, and 7 but showing an accumulator series.

FIG. 17 is a view similar to that of FIGS. 1, 6, 7 and 16 but showing another alternative arrangement for the accumulator series.

FIG. 18 is a view similar to that of FIGS. 1, 6, 7, 16 and 17 but showing another alternative arrangement for the accumulator series.

FIG. 19 is a view similar to that of FIGS. 1, 6, 7, 16, 17 and 18 but showing another alternative arrangement for the accumulator series.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention.

With attention to FIGS. 1 and 2, a bonding system 10 is disclosed wherein the positional accuracy of the bonding and quality of the bonding is improved over the prior art. As shown, the system 10 includes an ultrasonic bonder for bonding a plurality webs 12, or a folded web 12 having a front side 12A and a back side 12B. The system 10 includes a first anvil 14A, a second anvil 14B, a first ultrasonic horn 16A, and a second ultrasonic horn 16B. The anvils 14A, 14B are each provided with an anvil insert 18 having a predetermined profile. The first and second anvils 14A, 14B are laterally spaced apart inline and in a machine direction.

The system 10 includes carrying means for carrying the webs 12 so that the webs 12 pass a first gap between the first anvil 14A and the first ultrasonic horn 16A and then a second gap between the second anvil 14B and the second ultrasonic horn 16B. The first and second ultrasonic horns 16A, 16B apply vibration energy to the web 12 simultaneously and in cooperation with a respective anvil 14A, 14B to bond a respective portion of the web 12 that is to be an end portion 2C of an individual finished article (not shown in these views). As mentioned, the first anvil 14A and the first ultrasonic horn 16A are provided inline from the second anvil 14B and the second ultrasonic horn 16B and are spaced apart a predetermined distance d1 that corresponds to the distance between bonds 22. The predetermined distance d1 may be changed to accommodate various sizes of the finished product, since the distance d1 corresponds to the length of the individual article. Accordingly, the length of the individual article may be changed by adjusting the position of the first or second ultrasonic horn 16A, 16B with respect to the other ultrasonic horn 16A, 16B. Moreover, the system 10 includes a device for linear reciprocation of a selected anvil 14A, 14B and ultrasonic horn 16A, 16B relative another anvil 14A, 14B and ultrasonic horn 16A, 16B and to move in the direction of arrow A, (see FIG. 2) and to thereby change the distance d1, d2 between a selected anvil 14A, 14B and horn 16A, 16B and the adjacent anvil 14A, 14B and horn 16A, 16B. Preferably, the selected anvil 14A, 14B and ultrasonic horn is 16A, 16B slidingly mounted to a base structure (not shown), and its movement manually or computer controlled, as understood by one skilled in the art. Since the distance d1, d2 intervals of bonding positions may be changed by changing the position of the first or second ultrasonic horn 16A, 16B, the present system may easily produce individual articles of various sizes. It is to be understood that while the view of FIG. 2 illustrates movement of the second ultrasonic horn 16B, the position of the first ultrasonic horn 16A may also or alternatively be changeable, as required by a specific application.

With attention to FIGS. 6-11, the present system 10 may be seen to further comprise a velocity-changing device for increasing and decreasing the moving velocity of the web 12. The velocity-changing device preferably includes a first web festoon accumulator 24A having a first accumulator roller 30A, and a second web festoon accumulator 24B having a second accumulator roller 30B. The first web festoon accumulator 24A receives the webs 12 flowing from an upstream side and releases the webs toward the ultrasonic horns 16A, 16B while the second web festoon accumulator 24B receives the webs 12 from the ultrasonic horns 16A, 16B and moves the webs 12 toward a downstream side. The velocity-changing device further includes means for moving the first and second accumulator rollers 30A, 30B in a unison, linear manner to thereby change the velocity V1 of the web 12 received. As seen in FIG. 7, when the first and second accumulator rollers 30A, 30B move in the direction of arrow B, the velocity V1 of the web 12 from the upstream side is moved to second, slower velocity V2, such that the dwell time of the web 12 during the bonding operation is adequate for proper bonding. The anvil rolls 14A, 14B are preferably synchronized such that the device 10 will produce two bonds 22 simultaneously during the slower V2 velocity. Once the web 12 is bonded, the accumulator rollers 30A, 30B move in the direction of arrow C (see FIG. 8) and the webs 12 move at velocity V3 to be ultimately transported by the second web festoon accumulator 24B at the first V1 velocity and in a downstream direction.

The surfaces of the anvils 14A, 14B used in cooperation with the ultrasonic horns 16A, 16B may preferably include an anvil insert 18, as is shown in FIGS. 3-4C. The anvil insert 18 may include a seal surface, an embossing surface, or a combination thereof. The anvil insert 18 illustrated in these views includes a pair of spaced apart seal surfaces 26 having a recess 28 therebetween and wherein the seal surfaces 26 are provided with a series of canted rectangular patterns or teeth 32 thereon. The canted orientation of the rectangular pattern 32 provides both trailing edge and leading edge coverage in a cross-machine direction. This arrangement allows even wear on the horns 16A, 16B interfacing with the anvils 14A, 14B such that the need to re-grind worn horns 16A, 16B is greatly reduced. Moreover, the cost associated with anvil 14A, 14B assembly is reduced because the anvil 14A, 14B and the insert 18 may be manufactured separately and less material is required. Further, maintenance of the anvil 14A, 14B is easier and less costly since the user requires only a spare insert 18 rather than an entire anvil 14A, 14B when replacement is needed. Typical bond patterns produced by typical anvils (not shown) are not canted and are often merely a series of parallel rectangles (not shown). During use, these typical bond patterns may wear grooves into the surface of the horn 16A, 16B causing downtime for horn 16A, 16B maintenance. The pattern 32 disclosed in FIGS. 4, 4A, 4B and 4C reduces downtime for horn 16A, 16B maintenance. With particular reference to FIGS. 4A and 4B, it may be seen that the canted arrangement of the rectangles or teeth 32, creates a bond pattern that will evenly wear a corresponding ultrasonic horn 16A, 16B. As shown, the edges 34 of adjacent teeth 32 are parallel to one another for facile manufacture. Moreover, the teeth 32 are angled relative to the machine direction at a predetermined angle F (see FIG. 4A) that provides a following tooth 32 to fill in any gaps G (See FIG. 4C) existing between any preceding tooth 32. The view of FIG. 4C illustrates this particular feature in greater detail. Depending on the geometry, such as width of gap between teeth 32 rows, width of gap between teeth 32, and the like, the predetermined angle F may provide full coverage of the ultrasonic horn 16A, 16B to achieve the goal of even wear. While angling the teeth 32 provides more even wear of the ultrasonic horn 16A, 16B, structural liability of the teeth 32 may increase with the angle F. Structural integrity of the teeth 32 may be increased through the use of various radii between the teeth 32 (see FIG. 4B for example). By varying the radii between the teeth 32 such that each tooth has a small radius R2 on one side and a large radius R1 on the other, individual teeth 32 are more structurally sound and the chance of breaking a tooth 32 is greatly reduced. The anvil insert 18 of these views may be used to simultaneously bond adjacent article end portions 20, while reserving a boundary between the sealed end portions for a later severing operation.

With attention to FIGS. 12-15, it may be seen that a bonding system 10 according to the present invention may include a first anvil 14A, a second anvil 14B, a third anvil 14C, a first ultrasonic horn 16A, a second ultrasonic horn 16B, and a third ultrasonic horn 16C. The anvils 14A, 14B, 14C may be each provided with an anvil insert 18 having a predetermined profile, as described above. The anvils 14A, 14B, 14C are laterally spaced apart inline and in a machine direction. As in the previous embodiment, the ultrasonic horns 16A, 16B, 16C apply vibration energy to the web 12 simultaneously and in cooperation with a respective anvil 14A, 14B, 14C to bond a respective portion of the web 12 that is to be an end portion 20 of an individual finished article (not shown in these views). As previously described, the first anvil 14A and the first ultrasonic horn 16A are provided inline from the second anvil 14B and the second ultrasonic horn 16B, with the third anvil 14C and the third ultrasonic horn 16C provided inline from the second anvil 14B and the second ultrasonic horn 16B. The anvils 14A, 14B, 14C with the corresponding horns 16A, 16B, 16C are spaced apart a predetermined distance d3 that corresponds to the distance between bonds 22. The predetermined distance d3 may be changed to accommodate various sizes of the finished product, since the distance d3 corresponds to the length of the individual article. Accordingly, the length of the individual article may be changed by adjusting the position of the first, second, or third ultrasonic horn 16A, 16B, 16C with respect to any other ultrasonic horn 6A, 16B, 16C. Moreover, the system 10 includes a device for linear reciprocation of a selected anvil 14A, 14B, 14C and ultrasonic horn 16A, 16B, 16C relative to another anvil 14A, 14B, 14C and ultrasonic horn 16A, 16B, 16C and to move in the direction of arrow D, (see FIG. 13) and to thereby change the distance d3, d4 between a selected anvil 14A, 14B, 14C and horn 16A, 16B, 16C and the adjacent anvil 114A, 14B, 14C and horn 16A, 16B, 16C. As in the previously described arrangement, a selected anvil 14A, 14B, 14C and ultrasonic horn is 16A, 16B, 16C is preferably slidingly mounted to a base structure (not shown), and the movement manually or computer controlled, as understood by one skilled in the art. Since the distance d3, d4 intervals of bonding positions may be changed by changing the position of the first, second, or third ultrasonic horn 16A, 16B, 16C the present system may easily produce individual articles of various sizes. It is to be understood that while the views of FIGS. 12 and 13 illustrate movement of the first and third ultrasonic horns 16A, 16C, the position of the second ultrasonic horn 16B may also or alternatively be changeable, as required by a specific application. Moreover, the bonding system 10 may include any combination of fixed and moveable ultrasonic horns 16A, 16B, 16C, such as, but not limited to: one fixed ultrasonic horn, with two movable ultrasonic horns; two fixed ultrasonic horns and one movable ultrasonic horn; three fixed ultrasonic horns; and three movable ultrasonic horns, by way of non-limiting example.

FIGS. 14 and 15 illustrate another arrangement of anvils and ultrasonic horns. In these views anvil pairs 114A, 114B are utilized rather that the single anvils 14A, 14B, 14C illustrated in previous views. Moreover, ultrasonic horn pairs 116A, 116B correspond to and cooperate with the anvil pairs 114A, 114B.

FIGS. 16 and 17 illustrate an alternative arrangement and showing a vertical accumulator series 140 rather than the web festoon accumulator 24A, 24B and accumulator rollers 30A, 30B arrangement previously described. As shown, the accumulator series 140 may include any number of roll assemblies 130. It is to be understood that while specific numbers and arrangements of assemblies 130 are shown in the Figures, any number and arrangement of roll assemblies 130 may be envisioned without departing from the invention. Moreover, while not specifically shown, it is to be understood that the accumulator series 140 shown in FIGS. 16 and 17 may be used with any of the anvils 14A, 14B, 14C and ultrasonic horns 16A, 16B, 16C described and illustrated in previous views.

FIGS. 18 and 19 illustrate an alternative arrangement similar to that of FIGS. 16 and 17 but showing a horizontal accumulator series 140A. As shown, the accumulator series 140A may include any number of roll assemblies 130. As in the arrangements shown n FIGS. 16 and 17, it is to be understood that the specific number and arrangement of assemblies 130 shown in the Figures should not be considered limiting, and any number and arrangement of roll assemblies 130 may be envisioned without departing from the invention. Moreover, while not specifically shown, it is to be understood that accumulator series 140A shown in FIGS. 18 and 19 may be used with any of the anvils 14A, 14B, 14C and ultrasonic horns 16A, 16B, 16C described and illustrated in previous views.

The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 

We claim:
 1. A bonding system for bonding a web comprising at least a pair of web layers, the bonding system comprising: a first ultrasonic horn; and a first anvil spaced apart from the first ultrasonic horn by a gap so as to allow for translation of the web therethrough in a machine direction, the first anvil comprising a pair of seal surfaces extending in a cross-machine direction that is orthogonal to the machine direction and being spaced apart in the machine direction so as to have a recess therebetween; wherein each of the pair of seal surfaces comprises canted teeth formed thereon, the canted teeth angled so as to provide both trailing edge and leading edge coverage in the cross-machine direction; and wherein the first ultrasonic horn operates with the first anvil to ultrasonically bond the plurality of web layers together at a plurality of bond points corresponding to the canted teeth, as the web moves through the gap.
 2. The bonding system of claim 1 wherein the pair of seal surfaces comprises: a first seal surface having a first portion of the canted teeth thereon arranged in a first row; and a second seal surface having a second portion of the canted teeth thereon arranged in a second row.
 3. The bonding system of claim 2 wherein the canted teeth are angled relative to the machine direction at an angle such that the canted teeth in the second row fill in machine direction gaps between canted teeth in the first row.
 4. The bonding system of claim 1 wherein the web that is translated through the gap between the first ultrasonic horn and the first anvil comprises a continuous web that generally defines a plurality of disposable undergarment blanks; and wherein the plurality of bond points formed via functioning of the pair of seal surfaces with the ultrasonic horn comprises a first side seam adjacent a lateral edge of a first disposable undergarment blank and a second side seam spaced apart from the first side seam in the machine direction and adjacent a lateral edge of a second disposable undergarment blank, with the lateral edges of the first and second disposable undergarment blanks having the first and second side seams thereon being adjacent one another.
 5. The bonding system of claim 4 further comprising: a second ultrasonic horn; and a second anvil spaced apart from the second ultrasonic horn by a gap so as to allow for translation of the web therethrough in the machine direction, the second anvil comprising another pair of seal surfaces extending in the cross-machine direction and spaced apart in the machine direction so as to have a recess therebetween, each of the pair of another pair of seal surfaces comprising canted teeth formed thereon angled so as to provide both trailing edge and leading edge coverage in the cross-machine direction; wherein the second ultrasonic horn and the second anvil are spaced apart from the first ultrasonic horn and the first anvil in the machine direction and downstream therefrom; and wherein the second ultrasonic horn operates with the second anvil to ultrasonically bond the plurality of web layers together at another plurality of bond points corresponding to the another pair of seal surfaces.
 6. The bonding system of claim 5 further comprising an actuating device configured to linearly translate one of the first ultrasonic horn and first anvil pair or the second ultrasonic horn and second anvil pair in the machine direction, so as to selectively control a distance between the first ultrasonic horn and first anvil pair and the second ultrasonic horn and second anvil pair.
 7. The bonding system of claim 6 wherein the actuating device is configured to space apart the first ultrasonic horn and first anvil pair and the second ultrasonic horn and second anvil pair by a predetermined distance based on a size of the plurality of disposable undergarment blanks.
 8. The bonding system of claim 1 wherein the anvil comprises a rotary anvil that includes an anvil insert, and wherein the anvil insert includes the pair of seal surfaces thereon.
 9. The bonding system of claim 8 further comprising a feed unit that causes the web to move in the machine direction, so as to be fed through the gap between the first ultrasonic horn and the first anvil.
 10. The bonding system of claim 9 wherein the feed unit causes the web to move in the machine direction at a constant velocity.
 11. A method for bonding a continuous web comprising a plurality of web layers, the method comprising: providing a continuous web moving in a machine direction at a moving velocity; providing an anvil and ultrasonic horn along a path of the continuous web, wherein the anvil and ultrasonic horn are positioned on opposite sides of the continuous web and are spaced apart to provide a gap through which the continuous web passes; and ultrasonically bonding the plurality of web layers together at a plurality of bond points, via the ultrasonic horn functioning with the anvil, as the continuous web moves through the gap; wherein ultrasonically bonding the plurality of web layers together at the plurality of bond points comprises bonding the plurality of web layers together via a pair of seal surfaces on the anvil that extend in a cross-machine direction that is orthogonal to the machine direction and that are spaced apart from one another in the machine direction so as to have a recess therebetween, with each of the pair of seal surfaces comprising a row of canted teeth formed thereon angled so as to provide both trailing edge and leading edge coverage in the cross-machine direction, and with the plurality of bond points corresponding to locations of the canted teeth.
 12. The method of claim 11 wherein the continuous web generally defines a plurality of disposable undergarment blanks, and wherein the plurality of bond points forms a first side seam adjacent a lateral edge of a first disposable undergarment blank and a second side seam spaced apart from the first side seam in the machine direction and adjacent a lateral edge of a second disposable undergarment blank, with the lateral edges of the first and second disposable undergarment blanks having the first and second side seams thereon being adjacent one another.
 13. The method of claim 12 wherein a first seal surface of the pair of seal surfaces functions with the ultrasonic horn to form the first side seam and a second seal surface of the pair of seal surfaces functions with the ultrasonic horn to form the second side seam.
 14. The method of claim 13 wherein the canted teeth are angled relative to the machine direction at an angle such that the canted teeth on the second seal surface fill in machine direction gaps between canted teeth on the first seal surface.
 15. The method of claim 13 wherein the pair of seal surfaces are formed on an anvil insert affixed to the anvil.
 16. The method of claim 15 wherein the anvil comprises a rotary anvil having one or more anvil inserts affixed thereto, and wherein the continuous web moves in the machine direction at a constant velocity.
 17. The method of claim 12 wherein the anvil and ultrasonic horn comprise a first anvil and first ultrasonic horn, the method further comprising: providing a second anvil and second ultrasonic horn along the path of the continuous web and downstream from the first anvil and first ultrasonic horn; and ultrasonically bonding the plurality of web layers together at a plurality of bond points via the second ultrasonic horn functioning with the second anvil, wherein the plurality of web layers are bonded together via another pair of seal surfaces on the second anvil that extend in the cross-machine direction and are spaced apart from one another in the machine direction so as to have a recess therebetween, with each of the pair of seal surfaces comprising a row of canted teeth formed thereon angled so as to provide both trailing edge and leading edge coverage in the cross-machine direction, and with the plurality of bond points corresponding to locations of the canted teeth; wherein the plurality of bond points forms a third side seam adjacent an opposing lateral edge of the second disposable undergarment blank and a fourth side seam spaced apart from the third side seam in the machine direction and adjacent a lateral edge of a third disposable undergarment blank.
 18. The method of claim 17 further comprises spacing the first anvil and first ultrasonic horn apart in the machine direction from the second anvil and second ultrasonic horn by a predetermined distance based on a size of the plurality of disposable undergarment blanks. 